Kistler’s Process monitoring technology: Business success mantra for industrial manufacturers

August 13, 2018 1:46 pm

Kistler, the originator of piezoelectric measuring technology, is a global leader in dynamic pressure, force, torque and acceleration measurement. Cutting-edge technologies provide the basis for Kistler’s modular systems and services.
Anil Anand, Country Head, Kistler Instruments India Pvt. Ltd.

The vision of Industry 4.0 is already becoming a successful reality in numerous industrial applications, nowadays; in sectors such as automobile manufacturing, medical technology and electrical engineering. Unprecedented optimisation of all production processes is now possible thanks to increased digitisation and the growth of machine and system networking.

Effective way to optimise and control the entire production chain
Consistent control of the production chain, with zero-defect production as the goal, is essential for any modern production business to hold its feet in the market of the future. Just a few years ago, virtually, all products were still being inspected offline i.e. after the manufacturing process as such. Nowadays, by contrast, more and more products are actually monitored during the production process or ‘inline’ as a way of avoiding unnecessary costs. For joining, assembly and testing, sensor technology based on the piezoelectric principle is a fundamental factor in optimising production processes with zero-defect production as the goal. This technology is outstandingly suitable for measuring physical variables such as force, pressure, acceleration and torque.

Product testing with maXYmos TL: Higher quality and lower costs
By gradually expanding its product portfolio, Kistler has secured its reputation worldwide as one of the leading supplier of sensor systems. Thanks to the innovative development of the maXYmos family in particular, the uniformity of the systems and their simple, intuitive handling are now part of day-to-day industrial manufacturing operations. When testing products, users can access a simple system that enables them to perform various tests quickly and accurately; not only by force-displacement monitoring, but now also by monitoring the torque over time or angle of rotation.

With its wide range of interfaces, the system provides an ideal platform for recording a large number of measurands and their evaluation. Thanks to the user-friendly ‘sequencer mode’, test sequences can be programmed in the device and analysed online in real-time. These sequences can easily be parameterised on the device and perform simple control tasks.

System solutions for process-integrated quality assurance
So that the data captured by highly sensitive piezo sensors can actually be used, it is visualised, evaluated and documented in suitable monitoring systems. When these measuring systems are integrated into the manufacturing sequence, early detection of production defects become possible; thereby, reducing the potential risk of financial losses due to faulty parts.

In assembly technology, Kistler’s maXYmos system reliably monitors the production processes. The result is that the production can be optimised towards the goal of zero defect production with maximum cost efficiency. Outstanding features of the system are its exceptional flexibility and user-friendly operating interface. It can be used not only for automated joining and press-fit processes but also for manual operations such as pressing processes carried out by hand. In addition to production and assembly, applications for Kistler’s sensors and XY monitors include verifying the functionality of the end product. Thanks to the exceptional versatility of Kistler’s XY monitors, they can meet the requirements in all industrial sectors where quality assurance is becoming a prime consideration.

The maXYmos TL detects defective parts or deviations early in the production process and displays them transparently. This leads to minimised downtimes, optimised test sequences, and improved plant availability. Thus, the integrated process control enables higher quality and lower costs in assembly and testing.

Focusing on enhanced cost-effectiveness
Piezoelectric sensors and the related monitoring systems from Kistler are now being deployed in Europe, USA and Asia – in fact, across the entire globe. Sensor technology based on the piezoelectric principle delivers a remarkable increase in process reliability within a company’s production chain, coupled with a sustained improvement in productivity, opening up the way to zero-defect production and maximised process efficiency. From a business point of view, this high-precision technology serves one purpose above all others; it creates a sound basis for economic success in a market where competition is fierce in every part of the world.

Flexible joining with electromechanical servo technology
Customers who opt for electromechanical joining systems from Kistler benefit from major gains in flexibility and efficiency in the assembly process. The forces applied during press-fit processes can be monitored and controlled with precision; efficiency is many times higher than for hydraulic or even pneumatic technologies.

The spectrum ranges from the highly economical NCFE to the NCFR for complex applications. NCFE is especially suitable for simple joining processes in the 10 to 80 kN force range. NCFR has the extra advantage of hollow-shaft motors so that a rotary movement can be performed in addition to the press-fit process.

Customers in industry, research and development benefit from Kistler’s experience as a development partner, enabling them to optimise their products and processes so as to secure sustainable competitive edge. This Swiss corporation plays a key part in the evolution of automobile production and industrial automation, and its innovative sensor technology also
helps foster the development of many newly emerging sectors. Drawing on our extensive application expertise, and always with an absolute commitment to quality, Kistler drives innovations ahead in lightweight construction, vehicle safety, emission reduction and Industry 4.0.